Abstract: A method for manufacturing a crankshaft supporter having a bearing holding section that holds a bearing for supporting a crankshaft, and that is cast in aluminum alloy with a preform cast inside, the preform having a through hole extending therethrough. Provided are a core pin to process the through hole, and a pin hole shaped in the preform to accommodate the core pin. The core pin includes a pin insert section having an outer diameter less than inner diameter of the preform pin hole, and a head section having an outer diameter greater than the inner diameter of the preform pin hole. The pin hole insert section is inserted into the pin hole to contact the head section with an outer surface of the preform for securement inside a mold for casting. The core pin is removed during subsequent cutting of a larger diameter hole through the cast bearing holding section.

Abstract: In a battery post burning apparatus, the majority of the heat is supplied to the lead via the mold in which the finished post is being formed. The mold material in contact with the lead has a low thermal mass and high electrical and thermal resistance.

Abstract: An engine block mold package includes a barrel crankcase core having a plurality of barrels on each of which a respective cylinder bore liner is disposed. Each cylinder bore liner includes an inside diameter that is tapered along at least a portion of its length to match a draft angle present on the barrels to permit removal of the barrel crankcase core from a core box in which it is formed.

Abstract: Bimetallic plate is produced by providing a substrate of a first metal and, with the preheated substrate positioned in a mold cavity with a major surface of the substrate facing upwardly and to fill a portion of the depth of the cavity, a second metal is cast against that surface to form a cladding component and, with the substrate, to form the bimetallic plate. Prior to the cladding being cast, the major surface is rendered substantially oxide-free and is protected against oxidation. The cladding is cast by a melt, of a composition required for it, being poured at a superheated temperature whereby, with the preheating of the substrate, an overall heat energy balance is achieved between the substrate and the cladding.

Abstract: A method of infiltrating preformed, bonded-particulate components, such as rotary bits, for subterranean drilling manufactured by techniques such as layered-manufacturing or those employed in rapid prototyping technology. A support structure is provided for the preformed component to physically support the preformed component during various manufacturing processes such as sintering and infiltration.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces contamination of the engine block cast in the mold package by loose sand abraded off the cores during assembly. An assembly of multiple cores (core package) of the engine block mold package is formed apart from a base core. The core package is cleaned to remove loose sand therefrom. The cleaned core package then is positioned on the base core followed by assembly of a cover core to complete the engine block mold package for casting of an engine block therein.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces parting lines on the exterior surfaces of the mold package. An assembly of multiple cores (core package) is formed and includes multiple inter-core parting lines extending in different directions on exterior surfaces of the core assembly. The core package is disposed between a base core and a cover core configured to enclose the core package and form a single continuous exterior parting line about the assembled mold package.

Abstract: In assembly of engine block mold package, a water jacket slab core is assembled on a barrel crankcase core having a plurality of barrels on which cylinder bore liners are positioned. Some of the barrels include a core print on a distal end thereof. The water jacket slab core includes a plurality of core prints each in mating relation with a respective barrel core print and a plurality of bore liner positioning surfaces that each engage a respective distal end of a respective cylinder bore liner when the water jacket slab core is assembled on the barrels.

Abstract: A process for connecting at least two components, particularly body components of motor vehicles, wherein the first component has an undercut on a side facing the second component. In the area of the undercut, a connection piece is cast to the first component. The connection piece is designed such that, during its solidification, the connection piece is firmly connected with the first component by the contraction of a last-solidifying core area of the connection piece. Then the second component is mounted on the connection piece.

Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.

Abstract: A method of infiltrating preformed, bonded-particulate components, such as rotary bits, for subterranean drilling manufactured by techniques such as layered-manufacturing or those employed in rapid prototyping technology. A support structure is provided for the preformed component to physically support the preformed component during various manufacturing processes such as sintering and infiltration.

Abstract: The method includes the steps of a tape arranging step for arranging a support tape of a slide fastener on a mold having a capacity having a plurality of unit fastening element molding material grooves for molding a plurality of unit fastening elements, a molding material heating and discharge step for separating a molding material of more than two colors from a source material supply unit by the colors by a molding material injection means and then heating and discharging the same, a moving step for grouping external molding material flow paths from the molding material supply unit to an injection port of the mold into more than two groups and then moving different colors molding material by the colors, and an injection step for injecting the molding material into the unit fastening element molding material groove through a plurality of inject-on ports formed in the mold.

Abstract: A device for manufacturing an engine block has a casting mold with mold parts and cylinder liners. The mold parts have a seat with seat surfaces for each cylinder liner, and the opposed ends of the cylinder liner are seated in the seat surfaces. The cylinder liners become connected to the material cast in the casting mold and are removed together with the cast material from the mold parts after casting. The seat surfaces are conical and inclined at an incline angle relative to the cross-sectional plane of the cylinder liner seated in the seat such that the opposed ends of the cylinder liner remain seated at the seat surfaces upon heat expansion of the cylinder liner during preparation of the casting mold for casting and during casting.

Abstract: A method of infiltrating preformed, bonded-particulate components, such as rotary bits, for subterranean drilling manufactured by techniques such as layered-manufacturing or those employed in rapid prototyping technology. A support structure is provided for the preformed component to physically support the preformed component during various manufacturing processes such as sintering and infiltration.

Abstract: A process for manufacturing a heat sink, in which a plate-shaped base portion is formed by the diecasting method integrally with the one-end portions of a plurality of fins arrayed at a constant pitch and in parallel with each other.

Abstract: An improved bushing mold is disclosed for an apparatus for welding a battery terminal post to a battery bushing. The battery terminal post is electrically connected to a battery plate disposed within a battery case and the battery bushing is secured to a battery case cover with the bushing having a central bushing aperture for receiving the battery terminal post therein when the battery case cover is located on the battery case. The bushing mold comprises an electrically conductive mold body having an insulating mold insert. The mold insert comprises a first and a second insert portion with the second insert portion being replaceable independent of the first insert portion.

Abstract: An apparatus for die casting a rotor is disclosed, by which the die cast totors do not require reworking processes. An annular inner wall and an annular outer wall of a first mold are projected against an opposite surface of an intermediate die plate facing the movable die plate for inserting the inner wall and the outer wall into a sleeve. An annular first cavity is formed between the inner wall and the outer wall, and a plurality of sprues is penetrated from an upper surface of the first mold to an annular first cavity. A plurality of gates protrude from a bottom portion of the first cabity. Also, sizing bars inject high pressure water through spraying holes to clean the die plates.

Abstract: Equipment for the preparation of electric conducting composite samples by infiltration in a mold characterized in that it essentially comprises: a pressurization/infiltration chamber having at least one opening to connect it by means of appropriate tubes with a vacuum line and a pressure line and devices for sealing both under vacuum and under pressure; a sample-holder, inside said chamber, made of a material with a high thermal conductivity with one or more seats in each of which a mold is housed consisting of: a chemically inert and thermally stable tube made of a non-porous material; a plug, situated at one end of the tube, of a material which is different from the tube; a chemically inert and thermally stable spacer of non-porous material, situated inside the tube in contact with the plug; a device for creating a vacuum in the chamber; a device for pressurizing the chamber; a device for the thermal treatment of the sample-holder.

Abstract: There is disclosed an apparatus for casting a lead formation, particularly on the lug of a battery component. The lead is streamed over a mould block (20) defining a mould cavity (21) to flood the cavity (21). The flow of lead is maintained to raise the temperature of the block (20), at least adjacent the cavity, to achieve an appropriate working temperature.

Abstract: A number of strap-forming metal molds 12 corresponding to the number of steps are arranged on a circumferential track and are fed to the devices of the respective steps A.about.F together with electrode plate groups 10. Position A is an electrode plate group 10 introduction position; position B is a flux coating position in which electrode plate leads 6 are coated with flux; position C is an auxiliary heating position in which a mold 8 is heated to the temperature of the molten lead; position D is a molten lead pouring position in which molten lead is poured into a mold 8; position E is a strap-forming position in which electrode plate leads 6 are inserted into the molten lead, fused and cooled and the molten lead is solidified; position F is a discharge position in which a completed electrode plate assembly is discharged. Heating of a mold 8 is commenced by inductive heating from position F and is continued to position E.

Abstract: In a method of integrally attaching a hollow member to a cast product by casting so that the hollow member communicates with a hollow interior of the cast product, a closure member is fitted into an open end of the hollow member so that the open end of the hollow member is closed by the closure member. The closure member projects from a core for forming the hollow interior of the cast product in a direction different from a direction in which the core is drawn out of the cast product. A molten metal is poured into a casting mold after the casting mold has been clamped. The closure member is moved inside the core after solidification of the molten metal so that the closure member is released from the fitting in the hollow member. The core is drawn out of the solidified metal subsequently to the moving step of the closure member.

Abstract: The invention relates to an apparatus for casting a conductor of a cage rotor of an induction motor. A rotor core (13) comprising a laminated steel sheets is housed in a recess portion of a casting mold, an upper end portion thereof is held by a holding portion (70) and molten metal is supplied into a plurality of slots formed in the rotor core, thereby forming a plurality of conductor rods and a pair of end rings connecting the ends of the conductor rods with one another. The holding portion (70) comprises a cup (72) and a cylinder (73), and an axial dimension of the cup (72) is selected in correspondence to an axial dimension of the rotor core (13) housed in the recess portion of the casting mold. Further, by using a double cylinder (77, 79) in the holding portion (70), a rotor having higher quality can be obtained. For this reason, the same conductor casting apparatus can be used for casting the conductor of the rotor having different axial lengths and qualities depending on specifications.

Abstract: A system for manufacturing metal matrix composites, each including a porous preform infiltrated with molten metal, includes a programmable, automated arrangement for handling preforms for sequential introduction into a die caster of the system. A preform loader includes a reciprocable loading head which receives each preform from an associated stack, and delivers each preform to a horizontally reciprocable carrier of a preform shuttle. The preform shuttle effects indexed movement of each preform along a substantially horizontal path, through a preheating furnace, and into the die caster. Efficient operation of the system is promoted, while undesirable damage to the relatively brittle porous preforms is avoided.

Abstract: A male mold having a first cavity and a female mold with a second cavity are provided, the first cavity and the second cavity having a contour complimentary to that of a golf club head, a bottom wall defining one of the first cavity and the second cavity having a recess defined therein. An insert piece is inserted into the recess. Molten metal is poured into the first cavity and the second cavity to form the golf club head in which the insert piece is integrally formed with the golf club head.

Abstract: The apparatus includes an upper die, a replaceable first core member fixed to the cavity of the upper die by a screw, a titanium face plate for golf club head attached to the first core member and having notches and cuts for binding of molten alloy, a bottom die, and a second core member fixed to the cavity of the bottom die by a screw and having a projecting block raised from the top side corresponding to the sweat spot of the golf club head to be made for forming a hollow structure in the golf club head at the back of the sweat spot.

Abstract: A plurality of inter-connected cores includes barrel cores (18). Bore liners (10) surround the barrel cores (18) and are fixed in relation thereto. A cylinder block mold core package (22) is assembled from the cores (14, 24, 26, 28). The liners (10) are heated while they are within the cylinder block mold core package (22) by induction heating. To prevent migration, a mechanical interlock is provided between each liner (10) and its associated barrel core (18).

Abstract: A method of and an apparatus for applying hard material to cutting tool teeth (12), especially the teeth of saw blades (10). Due to its surface tension, the molten material (56) forms a spherical segment (58) in a mold cavity (40) which is defined around a tooth (12). The molten material (56) is cooled in the mold cavity (40) and subsequently heated again until it reaches a state which is at least approximately liquid. Only then is pressure, progressing in the direction towards the tip (18) of the tooth, applied to the spherical segment (58), whereby the latter is flattened. Hereby the precision in shape and durability of the teeth (12) is improved which are made of hard material (56), first molten and subsequently solidified.

Abstract: There is disclosed a mold for molding a box-shaped product having metal inserts each having a body and leg portions projecting from the product. The mold includes a pair of mold halves, and a core for placing the inserts thereon in such a manner that the body of the insert slightly spaced from the core, and that the body of the insert is disposed generally flush with or slightly spaced from a surface of one of the mold halves in which a cavity is formed. Slide cores, received respectively in grooves in the one mold half, for movement therealong in directions perpendicular to a direction of opening of the two mold halves, and each of the slide cores has a cavity portion which is to be aligned with the cavity in the one mold half.

Abstract: A cylinder block has a cylinder block body and a cylinder liner block mounted by casting in the cylinder block body. The cylinder liner block is formed from a material having a rigidity larger than that of the cylinder block body, and the cylinder liner block comprises a liner section mounted by casting in position in a cylinder barrel portion of the cylinder block body, and a reinforcing wall section mounted by casting in position in a bearing wall of a crank case portion of the cylinder block body. Thus, it is possible to increase the wear resistance of cylinders in the cylinder block, as well as to provide an increase in performance by reductions in vibration and noise of the engine including the cylinder block, and to provide reductions in size, weight and cost of the cylinder block by a reduction in thickness of the bearing walls.

Abstract: A decomposable casting core (56a, 56b) is formed in-situ with a sleeve-like liner member (64) and the assembly mounted within the mold cavity (24) of a cylinder block casting mold (22) for lining piston cylinder chambers (62a, 62b) of a cylinder block (26) cast within the mold (22). The liner member (64) is formed with an inner annular recess (80) which receives a corresponding annular projection (76) of the core (56a, 56b) for preventing the liner (64) from sliding axially on the core (56a, 56b) during casting.

Abstract: The horizontal type casting machine is capable of facilitating installation of a water jacket core and providing sufficient fluidity of the molten metal without generation of gas defect in casting a water-cooled type cylinder block. In the horizontal type casting machine, a cavity for the cylinder block is oriented vertically in which a cylinder bore portion of the cylinder block is positioned up and a crank chamber is positioned down. The cavity is defined by a stationary die, a movable die and movable cores. A movable slide core is provided movable relative to the movable die. When the movable slide core is moved to its retracted position, large working space is provided for installing the water jacket core at a given position. By the retracted movement of the movable slide core, large working space can be provided, thereby facilitating installation of the water jacket core. Further, since the water jacket core is set in its suspended fashion, easy positioning of the water jacket core results.

Abstract: The invention is directed to a method and a mold for forming a zinc collar on an insulator metal cap. The zinc collar forming mold is composed of a setting section for setting the metal cap in position on the mold and an upwardly opening cavity defined around the periphery of the setting section. For molding a zinc collar, the metal cap is immersed in a molten zinc, and the metal cap is set upright on the setting section of the mold with the lower half thereof being still in the molten state. Subsequenctly, a molten zinc is poured from the upper opening of the mold, and upon solidification of the molten zinc, a zinc collar can be formed around the external circumference of the metal cap.

Abstract: A bi-metallic extrusion billet perform is produced in a single casting. An inner core made of a desired material is placed in the center of a crucible or mold as a prepared bar. Molten cladding material is cast into an annular area between the outside surface of the inner core and an inner surface of the crucible or mold. Bottom pouring is enabled through the center of the inner core, which has been appropriately provided with a hole of a size that is consistent with the extrusion press and the required extruded hollow size involved in later manufacturing steps. The entire operation, including the melting of the cladding material, is advantageously performed under a vacuum to eliminate the risk of trapping air at an interface between the inner core and the cladding material cost therearound.

Abstract: Around a tooth, a molding cavity is formed which is closed at the tooth face and tooth flanks and in which the mold material forms a dome due to its surface tension. Said dome is flattened prior to the solidification of the material for approximation to the intended profile of the tooth back by exerting a pressure on the dome which pressure is moved progressively in the direction towards the tooth tip. When the hard material is melted with a gas or plasma jet the latter can be moved after the melting of the hard material in the direction towards the tooth tip over the dome. The gas jet is used to smooth the material after a first heating torch is used to melt the material.

Abstract: A die casting apparatus for forming rotors for electric motors. The apparatus includes a frame having at least two opposed stationary pressure plates and a rotating turret rotatively mounted betewen these stationary plates. The turret includes three apertures at three equally spaced locations around the turret. Tooling is arranged at each of the respective locations for forming a rotor. Compensating and casting tooling is located at a first station, pin pressing and trimming tooling is located at the second station and unloading and loading tooling is located at the third station. The operations at the respective stations proceed simultaneously. The operations are selected so that the combined operations of each of the stations will take approximately equal amounts of time.

Abstract: A mould for the repairing of a damaged portion of a rail head, the mould includes a pair of mould halves which engage the longitudinal sides of the rail so as to provide a cavity above the damaged portion of the rail, molten metal is subsequently delivered to the cavity which molten metal passes across the top of the rail. The molten metal is allowed to cool and excess metal is removed to restore the shape of the rail head.

Abstract: The cylindrical side wall of the mold cavity (8) has an inside diameter (D) which is greater than the largest existing ophthalmic lens diameter, and a generally cylindrical membrane (25) of elastomer material is disposed concentrically inside the mold cavity so that in conjunction with the cylindrical side wall of the cavity it defines a variable volume annular chamber (31), the membrane being expansible and retractable radially under the action of a fluid which is alternatively removed from and admitted to the annular chamber.

Abstract: A mold for producing connecting straps for lead batteries, particularly according to a cast-on-strap (COS) process or the like, is especially adapted for the simultaneous casting-in of a pole insert, and has wall thicknesses which vary inversely to changes in the thickness of the connecting strap. Heat transition adjusted to the local accumulation of material on the casting is thus achieved, and the development of unequal temperature conditions during the entire casting process is avoided.

Abstract: An apparatus for producing a compound material such as a fiber reinforced metal comprises a first retaining chamber into which molten matrix metal e.g. aluminum etc. is introduced, a plunger for applying a pressure to the molten matrix metal positioned below the first retaining chamber, a second retaining chamber adapted to receive reinforcement materials e.g. fibrous ceramics called "whisker", the second retaining chamber being in vertical alignment with the first retaining chamber so as to communicate therewith, a clamping device positioned above the second retaining chamber and supported movably in a vertical direction, and heating means provided in the first and second retaining chambers. The apparatus thus configured makes it possible to easily impregnate the molten matrix metal into space between the reinforcement materials, thus producing a reinforced compound material with high quality.

Abstract: This bearing ring is of the kind comprising, for contact with the semi-finished blank to be processed, a limited number of bearing areas appropriately distributed circumferentially around the axis of the assembly. The planes tangential to the ends of each of the bearing areas form between them a dihedron, the bearing surface that a bearing area of this kind provides being in practice generally convex.

Abstract: An apparatus (10) for molding metallic articles such as wheel weights (11). Opposed mold sections (108, 109) are carried on support plates (41, 42) that are movable within a stanchion (40) by virtue of an actuating means (45). A feed mechanism (115) delivers mounting clips (18) to one of the mold sections (109), and an escapement means (135) assures that only one clip (18) is delivered at a time. The actuating mechanism (45) sequentially closes the mold sections (108, 109) to form a cavity (100) therebetween, moves the closed mold sections (108, 109) into engagement with an injection tube (79) which mates with a sprue hole (111). The injection tube (79) also presents a positioning lug (180) accurately to rotate the clip (18) to its desired disposition.

Abstract: A core assembly is formed by molding a destructible plastic form around at least one insert and optionally around a non-destructible core. The core assembly can be used, for example, for casting engine cylinder heads having valve seat inserts integral therewith. The plastic form retains and supports the inserts until the precise time the plastic is replaced by the molten metal.

Abstract: A brake crown rotor is produced by casting in a mold the substantially cylindrical cast metal crown, and fusing to the upper portion thereof the outer perimeter of a round prefabricated sheet metal cover, the fusion taking place in the mold.

Abstract: A tool for forming electrical interconnections between the terminal ends of storage cell plate lugs. This tool is particularly suited to forming such welds between the terminal ends of plate lugs which project through a cell case wall.

Abstract: Apparatus and method for injecting molten lead from a reservoir into a die mold cavity formed about an aperture in the wall of a plastic battery for casting lead-alloy battery terminal connectors. Batteries are positioned adjacent the molten lead reservoir of the apparatus and mold portions move together to hold the battery containers in a clamp-like action. Molten lead is die cast under pressure into the mold cavity in which a stainless steel threaded nut is positioned. The lead is forced through a heated chamber into a portion of the mold which may be water cooled. The mold is designed to allow venting of gases, thereby eliminating porosity; and the apparatus is designed to provide casting which is free of jagged projections in the sprue hole.

Abstract: This blocking apparatus for fixing a metal block to the finished face of a semi-finished spectacle lens blank by casting a low-melting metal into a mold contacting the finished face of the blank comprises a mold made of two sections, namely a fixed section and a movable section, the former carrying the annular seat for the lens blank and the latter carrying relief elements, these two mold sections being in mutual rotary contact through part-spherical surfaces constituting a ball-joint centered to the axis of the annular seat. Control means are operatively connected to a shaft rigid with the movable mold portion for orienting same and cause same to be lipped about the center of the ball-joint in order to impart the prescribed prism value and the prescribed prism axis orientation, and align the relief elements with the prescribed cylinder axis.

Abstract: A composite mold construction for casting on the connector straps, posts, and terminals for lead acid electrical storage batteries wherein the mold cavity areas are alternately heated by direct flame on one face and then chilled by a coolant on their opposite face to freeze metal in the cavities without freezing molten metal flowing in adjacent flow channels. A plurality of mold cavity partition inserts are arranged to be interchangeable in the main mold assembly to enable a single mold assembly to be utilized for several arrangements of battery cells, strappings, and terminals. Thermal distortion of the mating parts is minimized to maintain the junctions between the insert and frame free of leaks by surface geometries which provide broad surfaces of contact drawn together by bolts securing the relatively thin inserts by tapped bores in the more massive primary portions of the mold assembly.

Abstract: Method for injecting molten lead from a reservoir into a die mold cavity formed about an aperture in the wall of a plastic battery for casting lead-alloy battery terminal connectors. Batteries are positioned adjacent the molten lead reservoir of the apparatus and mold portions move together to hold the battery containers in a clamp-like action. Molten lead is die cast under pressure into the mold cavity in which a stainless steel threaded nut is positioned. The lead is forced through a heated chamber into a portion of the mold which may be water cooled. The mold is designed to allow venting of gases, thereby eliminating porosity; and the apparatus is designed to provide casting which is free of jagged projections in the sprue hole. The aperture in the battery wall is surrounded by a series of plastic annular rings extending outward from the battery wall but being a part thereof. The molten lead surrounds the annular rings and fills the spaces therebetween when it is injected into the cavity.

Abstract: An automatic part loading unit for loading various diameter and stack height sizes of rotor assemblies into the compensator sleeves of multiple cavity rotor dies for the subsequent casting of the conductor bars and end rings of squirrel cage electrical motor rotors. The loading unit comprises a magazine section having a plurality of inclined guide tracks on which the rotor preforms are stacked, and an escapement mechanism which permits one rotor preform at a time to roll from each of the guide tracks in the magazine section onto respective inclined guide tracks leading to the breech openings of the die cavities. The guide tracks are laterally adjustable so as to accommodate rotor preforms of various stack height. As the rotor preforms roll down the inclined guide track toward the die cavities, they are decelerated by means of pivotally mounted, counterweighted arms which are contacted by and then swung out of the way by the rotors.

Abstract: In the invention, an apparatus is designed for producing spacer frames for insulating glass window structures, made up of lengths of hollow molding joined together by male cornerpieces. Hollows and spaces at the corner joins are sealed or filled by injection of a sealing composition forced in by the use of a female injection head designed to take up a frame corner, and a driver for pushing the frame corner structure into the injection head. There is furthermore a work table for the frame parts in the working position on injection of the compound or sealant, and gripper structures for keeping the hollow molding lengths, forming the corner, in the desired position. At least one of the gripper structures is able to be moved towards the put-in male part of the cornerpiece after the hollow molding part has been gripped.